Viessmann Vitovalor PT2 E11T Installation And Service Instructions Manual
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Viessmann Vitovalor PT2 E11T Installation And Service Instructions Manual

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VIESMANN
Installation and service instructions
for contractors
Vitovalor PT2
Type E11T, E19T, E25T, E32T, 0.9 to 30.8 kW
Fuel cell based micro CHP unit with integral gas condensing boiler and adjacent
cylinder module
Natural gas version
VITOVALOR PT2
Please keep safe.
5835783 GB
5/2019

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Summary of Contents for Viessmann Vitovalor PT2 E11T

  • Page 1 VIESMANN Installation and service instructions for contractors Vitovalor PT2 Type E11T, E19T, E25T, E32T, 0.9 to 30.8 kW Fuel cell based micro CHP unit with integral gas condensing boiler and adjacent cylinder module Natural gas version VITOVALOR PT2 Please keep safe. 5835783 GB 5/2019...
  • Page 2 Never touch hot surfaces on the boiler, burner, lidate our warranty. ■ flue system or pipework. For replacements, use only original spare parts supplied or approved by Viessmann. Please note Electronic assemblies can be damaged by elec- trostatic discharge. Prior to commencing work, touch earthed objects such as heating or water pipes to dis- charge static loads.
  • Page 3 Safety instructions Safety instructions (cont.) Safety instructions for operating the system If you smell gas Flue systems and combustion air Danger Ensure that flue systems are clear and cannot be Escaping gas can lead to explosions which may sealed, for instance due to accumulation of conden- result in serious injury.

  • Page 4: Table Of Contents

    Index Index 1. Information Disposal of packaging ................Symbols ....................Intended use ..................Product information ................Vitovalor PT2 ..................■ Note on positioning ................■ 2. Preparing for installation Handling ....................Siting ...................... Dimensions of siting options ............... ■ Preparing for installation ................ 12 Notes on connecting to the mains supply ..........
  • Page 5 Index Index 4. Commissioning, inspec- Steps - commissioning, inspection and maintenance ......47 tion, maintenance 5. System configuration Calling up parameters ................83 (parameters) General ....................83 Boiler ...................... 85 DHW ...................... 87 Heating circuit 1, Heating circuit 2, Heating circuit 3, Heating circuit 4 .. 88 Fuel cell ....................
  • Page 6 Index Index (cont.) Cylinder assembly ................. 180 Vitovalor cylinder module assembly ............182 Side mounting kit assembly ..............184 9. Function description Control unit .................... 186 Heating mode ..................186 ■ Heating the loading cylinder ............... 186 ■ Operating the fuel cell module ............186 ■...

  • Page 7: Symbols

    Information Disposal of packaging Please dispose of packaging waste in line with statu- tory regulations. Symbols The steps in connection with commissioning, inspec- Symbol Meaning tion and maintenance are found in the "Commission- Reference to other document containing ing, inspection and maintenance" section and identified further information as follows: Step in a diagram:...

  • Page 8: Product Information

    Information Intended use (cont.) Incorrect usage or operation of the appliance (e.g. the appliance being opened by the system user) is prohibi- ted and results in an exclusion of liability. Incorrect usage also occurs if the components in the heating system are modified from their intended use (e.g.

  • Page 9: Handling

    Preparing for installation Handling Gas condensing and fuel cell module: Please note ■ If possible, leave the modules in their packaging dur- Prevent damage to the appliance during han- ing handling. dling. ■ When transporting, keep upright at all times on the Never set the appliance down on its front or pallet or its base.
  • Page 10 Preparing for installation Siting (cont.) Installation versions for room heights > 2030 mm Cylinder module to the left of the gas condensing and fuel cell module 1205 Fig. 2 Wiring area Note Height of balanced flue terminal including balanced flue pipe 1000 mm in length.
  • Page 11 Preparing for installation Siting (cont.) Cylinder module to the right of the gas condensing and fuel cell module 1205 Fig. 3 Wiring area Note A special balanced flue inspection bend (can be deliv- Height of balanced flue terminal including balanced ered on request) is required for this installation version.

  • Page 12: Preparing For Installation

    Preparing for installation Siting (cont.) 1205 Fig. 4 Wiring area Preparing for installation Use a connection set – available as an accessory – to Preparing connections on site: make the connections on the water side. Connection set installation instructions Fitting accessories Before final siting, attach all of the accessories that are to be mounted from the back of the boiler (e.g.
  • Page 13 Preparing for installation Preparing for installation (cont.) 1205 Fig. 5 Condensate drain Observe the necessary fall. Clearance for connections on the water side Clearance for condensate drain pipe connection Note All height dimensions have a tolerance of +15 mm on account of the adjustable feet.
  • Page 14 Preparing for installation Preparing for installation (cont.) Connections on the water side with connection set (standard delivery) Fig. 6 Heating return R Heating flow R ¾ ¾ Cold water R Manometer and drain valve ½ DHW circulation R (accessory) Gas shut-off valve ½...

  • Page 15: Notes On Connecting To The Mains Supply

    [or local regulations] to the relevant grid operator. ity. Application forms [for German grid operators] are ■ The applicable DIN VDE guidelines, specifically available at www.viessmann.de. DIN VDE 0100, Part 701, DIN VDE 0100-551, DIN VDE 0126-1-1 and DIN VDE AR-N 4105 Note ■...
  • Page 16 Preparing for installation Notes on connecting to the mains supply (cont.) Arrangement of excess export system when con- Arrangement of excess export when connected nected into a sub-distribution board into a main LV distribution board 400V / 230V~ N AC 400V / 230V~ M Fig.

  • Page 17: Property Boundaries And Transfer Point Without Power Storage System

    Preparing for installation Notes on connecting to the mains supply (cont.) Property boundaries and transfer point without power storage system 400V / 230V~ Power distribution On-site consumers Short circuit protection Overload protection, RCD Vitovalor PT2 GS protection Inverter (DC/AC converter) S = 1.5 kVA EMAX Fuel cell...

  • Page 18: Property Boundaries And Transfer Point With Power Storage System

    Preparing for installation Notes on connecting to the mains supply (cont.) Property boundaries and transfer point with power storage system 400V / 230V~ Power distribution On-site consumers Short circuit protection Overload protection, RCD Vitovalor PT2 GS protection Inverter (DC/AC converter) S = 1.5 kVA EMAX Fuel cell...

  • Page 19: Connection For Excess Export Without Power Storage System

    Preparing for installation Notes on connecting to the mains supply (cont.) Connection for excess export without power storage system On-site energy consumption to paragraphs 33 and 4(3) of the German CHP Act (KWKG) 400V / 230V~ 1~/N/PE 1~/N/PE Fig. 11 Low voltage grid GS protection Main power supply...
  • Page 20 Preparing for installation Notes on connecting to the mains supply (cont.) Z2 Export meter for PV system power generation Z3 Export meter for power generation by Vitovalor PT2 (standard delivery with Vitovalor PT2) Z4 Export meter for Vitovalor PT2 alone...

  • Page 21: Connection For Excess Export With Power Storage System

    Preparing for installation Notes on connecting to the mains supply (cont.) Connection for excess export with power storage system On-site energy consumption to paragraphs 33 and 4(3) of the German CHP Act (KWKG) 400V / 230V~ 1~/N/PE 1~/N/PE Fig. 12 Low voltage grid On-site consumers Main power supply...

  • Page 22: Fuse Protection

    Preparing for installation Notes on connecting to the mains supply (cont.) GS protection for PV system Z1 Balancing bidirectional meter (observe meter cir- PV inverter cuit) Photovoltaic system Electricity meter for power export and drawing Power storage system inverter Z2 Export meter for PV system power generation Z3 Export meter for power generation by Power storage unit Vitovalor PT2 (standard delivery with...
  • Page 23 Preparing for installation Notes on connecting to the mains supply (cont.) Ensure adequate selectivity if the new RCD is installed downstream of an existing circuit breaker. In order to ensure complete selectivity of two residual current devices connected in series, the fault current of upstream RCD must be at least 3 times as high as that of RCD...

  • Page 24: Installing And Aligning The Vitovalor Pt2

    Installation sequence Installing and aligning the Vitovalor PT2 Fitting the connection lines on the gas condensing and fuel cell module The connection lines are provided separately packed in a box. Fig. 15 1. Fit the gas shut-off valve to the appliance gas line. Note Torque: 24 Nm Fit the supplied edge protector to the bottom opening...
  • Page 25 Installation sequence Installing and aligning the Vitovalor PT2 (cont.) 180° Fig. 16 Note Pull the hoses out of the appliance far enough to pre- vent unnecessary bends inside the appliance. Connecting hoses to the on-site waste water pipe: See page 33.

  • Page 26: Aligning The Gas Condensing And Fuel Cell Module At The Installation Site

    Installation sequence Installing and aligning the Vitovalor PT2 (cont.) Aligning the gas condensing and fuel cell module at the installation site Fig. 17 Fitting accessories Check before final siting: Are all of the accessories fit- ted, that are to be mounted from the back of the boiler (e.g.

  • Page 27: Fitting The Connection Set (Accessory) To The Cylinder Module

    Installation sequence Installing and aligning the Vitovalor PT2 (cont.) Fitting the connection set (accessory) to the cylinder module Fig. 18 1. Install fittings with integral air vent valve on the cyl- 4. Route 2 cables with plugs out of the inder module.

  • Page 28: Aligning The Cylinder Module At The Installation Site

    Installation sequence Installing and aligning the Vitovalor PT2 (cont.) Aligning the cylinder module at the installation site Fig. 19 Fitting accessories Check before final siting: Are all of the accessories fit- ted, that are to be mounted from the back of the boiler (e.g.

  • Page 29: Detaching The Front Panels Of The Gas Condensing And Fuel Cell Modules

    Installation sequence Installing and aligning the Vitovalor PT2 (cont.) Detaching the front panels of the gas condensing and fuel cell modules Fig. 20 Note Hook in the programming unit mounting bracket in the maintenance position. See page 49.

  • Page 30: Removing The Cylinder Module Front Panel

    Installation sequence Installing and aligning the Vitovalor PT2 (cont.) Removing the cylinder module front panel Fig. 21...

  • Page 31: Removing The Module Connection Lines

    Installation sequence Installing and aligning the Vitovalor PT2 (cont.) Removing the module connection lines Fig. 22 Heating water and DHW connections Fig. 23 The illustration shows the connection set available as an accessory. Heating return R DHW R ¾ ½ Cold water R Heating flow R ½...

  • Page 32: Safety Assembly To Din 1988 And En 806 At The Cold Water Connection

    GmbH flue system" labels in conjunction with the ening poisoning due to carbon monoxide in the Viessmann flue system made by Skoberne. flue gas. Ensure the flue system functions correctly. Aper- Do not carry out commissioning until the following...

  • Page 33: Condensate Connection

    Installation sequence Condensate connection Route condensate hoses from the side openings to the building's drainage system. Connect hoses with a con- stant fall and a pipe vent to the building's drainage sys- tem. If required, install a condensate removal pump (acces- sories).

  • Page 34: Opening The Control Unit Enclosure On The Gas Condensing And Fuel Cell Module

    Installation sequence Opening the control unit enclosure on the gas condensing and fuel cell module Fig. 27 1. Undo 2 self-tapping screws and remove the trans- Please note port locking plate. Electronic assemblies can be damaged by elec- trostatic discharge. 2.

  • Page 35: Connecting The Cylinder Module Power Supply And Plusbus

    Installation sequence Electrical connections (cont.) Connections to 230 V~ plugs To the burner control unit fÖ Power supply from the power distribution board From the cylinder module External demand/blocking and switched power From the cylinder module outlet To the fuel cell module Switched power outlet To the M-Bus gateway P1 Parametrisable power outlet for e.g.

  • Page 36: Connecting The Cylinder Module Outlet Temperature Sensor

    Installation sequence Electrical connections (cont.) Connecting the cylinder module outlet temperature sensor Fig. 30 1. Route the sensor lead through the openings with 2. Plug the sensor lead connector onto the outlet tem- edge protection. perature sensor. Outside temperature sensor Fitting location for outside temperature sensor ■...

  • Page 37: Cylinder Module Control Unit

    Installation sequence Electrical connections (cont.) Cylinder module control unit Moving the cylinder module control unit for easier access Fig. 32...
  • Page 38 Installation sequence Electrical connections (cont.) Connections on the cylinder module control unit The mains connection and PlusBus connection of accessories are made on the cylinder module control unit. TS4 17 Fig. 33 A Cylinder temperature sensor top (connected in the delivered condition) B Cylinder temperature sensor bottom (con- nected in the delivered condition) Return temperature sensor (connected in the...

  • Page 39: Power Supply For Accessories (230 V ~)

    Installation sequence Electrical connections (cont.) Connecting the DHW circulation pump (accessory or on site) Specification Rated current Recommended connecting H05VV-F3G 0.75 mm cable H05RN-F3G 0.75 mm Fig. 34 DHW circulation pump Plug on the cylinder module control unit Power supply for accessories (230 V ~) Where the boiler is sited in a wet room, accessories If the total system current exceeds 6 A, connect one or outside the wet area must not be connected to the...

  • Page 40: Power Supply To The System

    Installation sequence Electrical connections (cont.) If the current flowing to the connected working parts PlusBus system length max. 50 m for 0.34 mm cable (e.g. circulation pumps) is higher than the fuse rating cross-section and unshielded cable. of the relevant accessory, only use the output con- cerned to control an on-site relay.

  • Page 41: Checking The Can Bus Terminator Setting

    Installation sequence Electrical connections (cont.) Checking the CAN bus terminator setting Switch on the gas condensing boiler must be set to "I". If Vitovalor PT2 is integrated in a CAN bus system and is located at the beginning or end of this CAN bus sys- tem (not in the middle), the terminator must be set to ON.

  • Page 42: Fitting The Front Panels Of The Gas Condensing And Fuel Cell Module

    Installation sequence Fitting the front panels of the gas condensing and fuel cell module Fig. 39 Fitting the programming unit Fig. 40 Light bar at the bottom...

  • Page 43: Fitting The Cylinder Module Front Panel

    Installation sequence Fitting the cylinder module front panel Move the cylinder module control unit back again. See page 37. Fig. 41...

  • Page 44: Splitting The Gas Condensing And Fuel Cell Modules

    Installation sequence Splitting the gas condensing and fuel cell modules If required for easier handling. Note Residual water may escape during dismantling. Fig. 42...
  • Page 45 Installation sequence Splitting the gas condensing and fuel cell… (cont.) Fig. 43...

  • Page 46: Reassemble The Gas Condensing And Fuel Cell Module In Reverse Order

    Installation sequence Splitting the gas condensing and fuel cell… (cont.) 3. 4x 8. 3. Fig. 44 Note Move lines with it when removing the gas condensing module. Reassemble the gas condensing and fuel cell module in reverse order. Use cable ties to re-secure the condensate pipe con- Note nection piece in the factory position.

  • Page 47: Commissioning, Inspec-Steps - Commissioning, Inspection And Maintenance

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance Commissioning steps Inspection steps Maintenance steps Page • • • 1. Removing the front panels....................49 • 2. Checking the power supply • 3. Overview of water circuits....................50 • 4. Filling the fuel cell module system separation circuit............ 50 •...
  • Page 48 Commissioning, inspection, maintenance Steps - commissioning, inspection and… (cont.) Commissioning steps Inspection steps Maintenance steps Page • • • 38. Checking the electrical connections for firm seating • • • 39. Checking for tightness the gas-bearing parts of the gas condensing module and connections to the fuel cell module under operating pressure........

  • Page 49: Removing The Front Panels

    Commissioning, inspection, maintenance Removing the front panels See page 29. Placing the programming unit in the maintenance position Fig. 45 Note The programming unit can be hung on the appliance in the maintenance position for commissioning and main- tenance. Do not disconnect the connection cable. Checking the power supply...

  • Page 50: Overview Of Water Circuits

    Commissioning, inspection, maintenance Overview of water circuits Fig. 46 The system has three separate water circuits, each Fuel cell module process circuit with different requirements in terms of the quality of fill water, plus the DHW water circuit. Gas condensing module and heating circuits (page 52) Fuel cell module system separation circuit (page 50)
  • Page 51 Commissioning, inspection, maintenance Filling the fuel cell module system separation… (cont.) Fig. 47 01. Close the gas shut-off valve. 07. Remove cap from drain & fill valve and con- nect the fill hose. 02. Push the supplied drain hose (4 m long) onto fit- ting at vent connection .

  • Page 52: Filling The Gas Condensing Module And Heating Circuits

    Commissioning, inspection, maintenance Filling the fuel cell module system separation… (cont.) 09. Fill with water until no more air escapes from vent 15. Significantly reduce the inflow on drain & fill connection valve Note 16. Check the charge pressure on pressure gauge Ensure that the pressure in the system separation and slowly close vent connection and drain &...
  • Page 53 Commissioning, inspection, maintenance Filling the gas condensing module and heating… (cont.) Total heating output Specific system volume < 20 l/kW 20 l/kW to < 50 l/kW 50 l/kW ≥ ≥ 200 to > ≤ 1.5 mol/m (8.4 °dH) 0.02 mol/m (0.11 °dH) <...
  • Page 54 Commissioning, inspection, maintenance Filling the gas condensing module and heating… (cont.) 01. Check the pre-charge pressure of the on-site dia- 08. Fill with water until no more air escapes from air phragm expansion vessel. See page 77. vent valve 02. Close the gas shut-off valve. 09.

  • Page 55: Filling The Dhw Cylinder

    Commissioning, inspection, maintenance Filling the DHW cylinder Fig. 50 1. Open shut-off valves in the cylinder 3. The DHW cylinder has been completely filled when no more air flows out of the DHW draw-off point. loading circuit. Switch on the gas condensing module ON/OFF 2.

  • Page 56: Filling The Fuel Cell Module Trap

    Commissioning, inspection, maintenance Filling the trap on the gas condensing module… (cont.) Fig. 51 1. For easier access, undo 2 screws and remove the 5. Fill trap with water and refit. mains distributor box. 6. Refit the hoses. Note If the module layout allows, the l.h. side panel can 7.
  • Page 57 Commissioning, inspection, maintenance Filling the fuel cell module trap (cont.) 5. Fill with distilled water (VDE 0510) until water runs from the trap drain on the rear. Distilled water (5 l) is available as an accessory (see parts list). Please note Commissioning with non-distilled water (VDE 0510) (e.g.

  • Page 58: Switching On The Gas Condensing Module And The Fuel Cell Module

    Commissioning, inspection, maintenance Switching on the gas condensing module and the fuel cell module Fig. 53 Gas condensing module ON/OFF switch Fuel cell module ON/OFF switch Export meter Z2 ON/OFF switch on the fuel cell module 1. Close the gas shut-off valve. 2.

  • Page 59: Setting The Max. Heating Output (Gas Condensing Module)

    Commissioning, inspection, maintenance Venting the heating system (cont.) 6. Use " " to activate the venting function. The venting function ends automatically after 20 min or when you tap " ". Setting the max. heating output (gas condensing module) A limit can be set on the maximum heating output for The adjustment is made in parameter 596 "Maximum heating mode.
  • Page 60 Commissioning, inspection, maintenance Commissioning the system (cont.) 7. Setting the function of floating switching contact 8. Setting function of EM-EA1 extension: plug ■ No function (delivered condition) ■ No function (delivered condition) ■ Fault message input 24 V on digital input DI1: ■...

  • Page 61: Naming The Heating Circuits

    Commissioning, inspection, maintenance Commissioning the system (cont.) 4. " " to confirm 5. "Commissioning" Naming the heating circuits In the delivered condition, the heating circuits are des- To enter names for heating circuits: ignated "Heating circuit 1", "Heating circuit 2", Operating instructions "Heating circuit ..."...
  • Page 62 Commissioning, inspection, maintenance Checking the static pressure and supply pressure (cont.) On the gas condensing module Fig. 55 01. Swivel off control unit enclosure . See page 34. 08. Check the supply (flow) pressure. Set value: 20 mbar (2.0 kPa) 02.

  • Page 63: Function Sequence And Possible Faults (Gas Condensing Module)

    Commissioning, inspection, maintenance Checking the static pressure and supply pressure (cont.) Supply pressure (flow pressure) Measures Below 17.4 mbar (1.74 kPa) Do not commission the appliance. Notify the gas supply utility. 17.4 to 25 mbar (1.74 to 2.5 kPa) Start up the appliance. Above 25 mbar (2.5 kPa) Connect the separate gas pressure governor upstream of the system and set the pre-charge pressure to 20 mbar (2.0 kPa).

  • Page 64: Fuel Cell Module Commissioning

    Fuel cell module commissioning Further commissioning of the fuel cell module may If the gas condensing module is going to be oper- only be carried out by Viessmann Technical Service or ated before commissioning the fuel cell module: a certified heating contractor.
  • Page 65 Commissioning, inspection, maintenance Starting maintenance mode (cont.) Removing cover from programming unit Fig. 56 Programming unit ITEM STATE Fig. 57 Function display No function Status Power supply indicator Commissioning indicator (flashing or constant) Fault indicator Confirm selection/adjustment Commissioning/maintenance indicator Select/adjust value Power generation indicator Note The display switches off when, in standard mode...

  • Page 66: Changing The Gas Type On The Fuel Cell Module

    Commissioning, inspection, maintenance Changing the gas type on the fuel cell module Delivered condition: Gas type "E" 1. Use / to select "94". Conversion is only required for operation with gas type "LL". 2. Press SET to confirm. Note 3. Use / to select gas type "E" or "LL". An incorrectly set gas type can result in faults on the fuel cell module.
  • Page 67 Commissioning, inspection, maintenance Filling with distilled water and starting the… (cont.) 09. Fill with distilled water (VDE 0510). Distilled water (5 l) is available as an accessory (see parts list). When indicators "01" to "02" are flashing: Fill with distilled water until water runs out of the trap drain at the rear.

  • Page 68: Terminating Maintenance Mode And Activating Energy Manager

    Switch the fuel cell module OFF and ON using the ON/OFF switch and initiate a new starting procedure. If a fault occurs again or the cause of the fault is ■ unclear, notify Viessmann technical services. Fault messages Display in STATE Cause Remedy No heat transfer from the fuel Remedy the cause for the lack of heat transfer.

  • Page 69: Tightness Test On Balanced Flue System (Annular Gap Check)

    Commissioning, inspection, maintenance Tightness test on balanced flue system (annular gap check) Fig. 59 Combustion air aperture (ventilation air) Note Only the gas condensing module may be operational during the annular gap test procedure. ■ Disable power generation by the fuel cell module before starting the test.

  • Page 70: Burner Removal (Gas Condensing Module)

    Commissioning, inspection, maintenance Burner removal (gas condensing module) Fig. 60 1. Turn off the ON/OFF switch on the mains distri- 4. Undo the fitting from gas supply pipe bution box. 5. Undo four screws and remove the burner. 2. Close gas shut-off valve and safeguard against reopening.

  • Page 71: Checking The Burner Gasket And Burner Gauze Assembly (Gas Condensing Module)

    Commissioning, inspection, maintenance Checking the burner gasket and burner gauze assembly (gas condensing module) Fig. 61 Check burner gauze assembly , electrodes 6. Insert thermal insulation ring and burner gauze gasket for damage. Only remove and replace com- assembly with gasket .

  • Page 72: Checking The Back Draught Safety Device

    Commissioning, inspection, maintenance Checking the back draught safety device 1. Undo 2 screws and remove fan 2. Remove back draught safety device 3. Check the damper and gasket of the back draught safety device for contamination and damage. Replace if necessary. 4.

  • Page 73: Cleaning Heating Surfaces (Gas Condensing Module)

    Commissioning, inspection, maintenance Cleaning heating surfaces (gas condensing module) Please note Scratches to the surfaces of the heat exchanger that come into contact with hot gas can result in corrosion damage. Brushing can cause deposits to become lodged in the gaps between the coils. Never use brushes to clean the heating sur- faces.

  • Page 74: Fitting The Burner (Gas Condensing Module)

    Commissioning, inspection, maintenance Checking condensate drain and cleaning the trap… (cont.) 1. For easier access, undo 2 screws and remove the 6. Fill trap with water and refit. mains distributor box. 7. Refit the hoses. Note If the module layout allows, the l.h. side panel can 8.

  • Page 75: Yearly Maintenance Of Fuel Cell Module

    Commissioning, inspection, maintenance 5-yearly maintenance of fuel cell module Note Before carrying out the maintenance work: ■ The fuel cell module must be in maintenance mode. Start maintenance mode, see page 64. ■ The distilled water must have been drained. Draining the distilled water Note This is required for the following maintenance work.

  • Page 76: Yearly Maintenance Of Fuel Cell Module

    "34" will appear on the display. In such a case, inform Viessmann Technical Services. 4. Press and hold SET for at least 3 s. 1. Turn on the ON/OFF switch on the fuel cell mod- "_CL"...

  • Page 77: Checking The Diaphragm Expansion Vessel And Pressure In The System Separation Circuit

    Commissioning, inspection, maintenance Checking the diaphragm expansion vessel and pressure in the system separation circuit Fig. 68 Note 3. If the pre-charge pressure of the diaphragm expan- Carry out this test on a cold system. sion vessel is lower than this, recharge with nitro- The system must be shut down.

  • Page 78: Checking For Tightness The Gas-Bearing Parts Of The Gas Condensing Module And Connections To The Fuel Cell Module Under Operating Pressure

    Commissioning, inspection, maintenance Checking the external diaphragm expansion… (cont.) 3. Top up with water until the charge pressure of the cooled system is at least 1.7 bar (0.17 MPa), and is 0.6 to 0.7 bar (60 to 70 kPa) higher than the pre- charge pressure of the expansion vessel.
  • Page 79 Commissioning, inspection, maintenance Checking the combustion quality (cont.) Fig. 69 1. Connect a flue gas analyser at flue gas port 02. "Service" the boiler flue connection. 03. Enter password "viservice". 2. Open the gas shut-off valve, start the boiler and create a heat demand.

  • Page 80: Adjusting Heating Curves

    Commissioning, inspection, maintenance Checking the combustion quality (cont.) Fuel cell module 1. Connect a flue gas analyser at flue gas port Note A CO or O test on the fuel cell module is not neces- the boiler flue connection. sary. Note The fuel cell module must be in operation (power generation) for the measurement.

  • Page 81: Checking And Resetting "Service" On The Programming Unit Of The Gas Condensing Module

    Commissioning, inspection, maintenance Adjusting heating curves (cont.) The heating curve is offset along the set room temper- Changing the reduced set room temperature ature axis. The start and stop points of the heating cir- cuit pumps depend on the Heating limit... outside tem- Operating instructions perature, heating circuit...

  • Page 82: Mounting The Cover Panel And Front Panel (Fuel Cell Module)

    Commissioning, inspection, maintenance Checking and resetting "Service" on the… (cont.) Acknowledging a service 2. "Service" to acknowledge the maintenance messages 3. Enter password "viservice". to confirm 4. "Service functions" Note 5. "Maintenance reset" An acknowledged service message that was not reset reappears the following Monday.

  • Page 83: System Configuration Calling Up Parameters

    System configuration (parameters) Calling up parameters Parameters are split into the following groups: 2. "Service" ■ – "General" – "Boiler" 3. Enter password "viservice". – "DHW" – "Heating circuit 1/2/3/4" 4. "System configuration" "Fuel cell" – Heating systems with one heating circuit without 5.
  • Page 84 System configuration (parameters) General (cont.) 897.0 "Screed drying" Setting Explanations Not active Screed drying can be set in accordance with selecta- ble temperature/time profiles. Diagram 1 Diagram 2 Diagram 3 Diagram 4 Diagram 5 Diagram 6 912.0 "Automatic summer/wintertime changeover" Setting Explanations Automatic changeover disabled...

  • Page 85: Boiler

    System configuration (parameters) General (cont.) 1098.5 "Calorific value" Setting Explanations Value is provided on the gas supplier's bill. Used for gas consumption data. 10.0000 5.0000 to Calorific value adjustable from 5.0000 to 40.0000 40.0000 kWh/m in increments of 0.0001 1139.0 "Outside temperature limit for cancelling reduced set room temperature" Setting Explanations Temperature limit for cancelling reduced set room...
  • Page 86 System configuration (parameters) Boiler (cont.) 522.3 "Interval until the next service" Setting Explanations Interval until the next service No interval selected 3 months 6 months 12 months 18 months 24 months 1411.0 "Clear maintenance messages" Setting Explanations Clear maintenance messages once maintenance has been performed.

  • Page 87: Dhw

    System configuration (parameters) Boiler (cont.) 1432.1 "Residual head control of primary circuit pump" Setting Explanations Residual head limit value for reducing pump speed of the internal circulation pump, in mbar Internal circulation pump is controlled in line with the outside temperature 1 to 255 Internal circulation pump is operated with constant re- sidual head.

  • Page 88: Heating Circuit 1, Heating Circuit 2, Heating Circuit 3, Heating Circuit 4

    System configuration (parameters) (cont.) 503.0 "Scald protection" Setting Explanations The adjustable water temperature is limited to a maxi- mum value. Scald protection OFF Danger Risk of injury due to increased DHW tempera- ture. Inform the system user of the risk from the high- er outlet temperature at the taps.
  • Page 89 System configuration (parameters) Heating circuit 1, Heating circuit 2, Heating… (cont.) 424.4 "Duration for set flow temperature increase, heating circuit 1" Setting Explanations Duration for set flow temperature increase See also chapter "Function description" 60 min Delivered condition 60 min 0 to 120 Temperature rise adjustable from 0 to 120 min 426.3 "Set flow temperature increased when switching from operation with reduced room temperature to...
  • Page 90 System configuration (parameters) Heating circuit 1, Heating circuit 2, Heating… (cont.) 430.4 "Duration for set flow temperature increase, heating circuit 4" Setting Explanations Duration for set flow temperature increase See also chapter "Function description" 60 min Delivered condition 60 min 0 to 120 Temperature rise adjustable from 0 to 120 min 933.3 "Priority, DHW heating, heating circuit 1"...
  • Page 91 System configuration (parameters) Heating circuit 1, Heating circuit 2, Heating… (cont.) 934.6 "Operating mode, heating circuit 2" Setting Explanations See also parameter 934.7 Heating mode: Weather-compensated without room tem- Weather-compensated without room temperature in- perature hook-up fluence Weather-compensated with room tempera- Weather-compensated with room temperature influ- ture hook-up ence...
  • Page 92 System configuration (parameters) Heating circuit 1, Heating circuit 2, Heating… (cont.) 935.7 "Room influence factor, heating circuit 3" Setting Explanations The higher the value, the greater the influence of the room temperature on the set flow temperature of the heating circuit (heating curve). Operation with room temperature hook-up must be set for the heating cir- cuit (parameter 935.6).
  • Page 93 System configuration (parameters) Heating circuit 1, Heating circuit 2, Heating… (cont.) 1102.0 "Min. speed of speed-controlled primary/heating circuit pump in standard mode, heating circuit 1" Setting Explanations Minimum speed of the internal circulation pump in heating mode with standard room temperature Delivered condition specified by settings specific to the heat generator 0 to 100...
  • Page 94 System configuration (parameters) Heating circuit 1, Heating circuit 2, Heating… (cont.) 1194.1 "Maximum flow temperature limit, heating circuit 3" Setting Explanations Maximum flow temperature limit for the heating circuit 74 °C Maximum limit in the delivered condition 74 °C 10 to 100 Setting range limited by heat generator-specific pa- rameters 1195.0 "Minimum flow temperature limit, heating circuit 4"...

  • Page 95: Fuel Cell

    System configuration (parameters) Heating circuit 1, Heating circuit 2, Heating… (cont.) 1397.0 "Heating limit: Economy function, outside temperature, heating circuit 3" Setting Explanations Heating circuit pump logic function (summer economy control): Heating circuit pump switches off when out- side temperature 1 K above selected value. Heating circuit pump switches back on when outside tempera- ture 1 K below selected value.
  • Page 96 System configuration (parameters) Fuel cell (cont.) 1098.0 "Gas price" per m Setting Explanations Gas price per m 0.053 Gas price in the delivered condition 0.053 0.001 to Adjustable from 0.001 to 5.0 1431.0 "CO2 factor gas per kWh" Setting Explanations factor gas in kg/kWh 0.23 Factor in the delivered condition 230 g/kWh...

  • Page 97: Diagnosis And Service Gas Condensing Module

    Diagnosis and service checks Gas condensing module Service menu Calling up the service menu Note to return to "Service, main menu" Tap the following buttons: Exiting the service menu 1. " " Tap the following buttons: 2. "Service menu" "Exit service". 3.

  • Page 98: Resetting All Passwords To The Factory Setting

    Resetting all passwords to the factory setting Tap the following buttons: 5. "Change passwords" 1. Request the master password from the Technical 6. "Reset all passwords" Service at the Viessmann Group. 7. Enter master password. 2. " " 8. Confirm twice with 3.
  • Page 99 Diagnosis and service checks Gas condensing module (cont.) 4. "Actuator and sensor test" 7. Tap the required actuator function. Several func- tions can be activated simultaneously. to confirm the security prompt. 8. If necessary, tap to confirm. The functions are Note active for 30 s.

  • Page 100: Fuel Cell Module

    Diagnosis and service checks Gas condensing module (cont.) Display Explanation Mixer HC2 Open Output for "Mixer open" active (extension heating circuit with mixer) Mixer HC2 Stop Current position is maintained (extension heating circuit with mixer) Mixer HC2 Close Output for "Mixer close" active (extension heating circuit with mixer) Mixer HC3 Open Output for "Mixer open"...

  • Page 101: Checking The Gas Consumption To Reclaim Fuel Tax

    Diagnosis and service checks Fuel cell module (cont.) Checking the gas consumption to reclaim fuel tax Operating instructions for Vitovalor PT2 Checking operating condition Operating instructions for Vitovalor PT2 Checking grid monitoring parameters ITEM STATE Fig. 74 1. Remove cover 2.

  • Page 102: Removing The Sd Card

    Diagnosis and service checks Fuel cell module (cont.) ITEM Meaning Set value Response time Min. frequency 47.5 Hz 200 ms Max. frequency 51.5 Hz 200 ms Note The table lists example set values for Germany. Removing the SD card The SD card is delivered already in place. Data stor- age for the fuel cell module begins as soon the Vitovalor PT2 is commissioned.

  • Page 103: Troubleshooting Fault Indicator On The Programming Unit

    Troubleshooting Fault indicator on the programming unit In case of a fault, is displayed and the light bar Calling up fault messages from the fault memory flashes orange. (message history) Note The 10 most recent faults (including those remedied) If a central fault message facility is connected, this is and service messages are saved and can be called switched on.

  • Page 104: Fault Messages For Gas Condensing Module

    Troubleshooting Fault messages for gas condensing module Fault number System characteristics Cause Measures on the display Burner in a fault state Lead break, flow tempera- Check flow temperature sensor on ture sensor the burner control unit (see page 130). Reset burner. Burner in a fault state Short circuit, flow temper- Check flow temperature sensor on...
  • Page 105 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.38 Burner blocked, heat genera- Short circuit, water pres- Check the water pressure sensor. tor circulation pump OFF sure sensor No central heating and no DHW heating F.49 Burner in a fault state...
  • Page 106 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.65 Burner in a fault state Flame signal is not Check gas supply (gas pressure present or insufficient at and gas flow switch). burner start.
  • Page 107 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.69 Burner in a fault state Ionisation current lies out- Check ionisation electrode and side the permissible range connecting cable. Check system for condensate backup.
  • Page 108 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.97 Function on digital input DI2 DIO extension PCB faulty Replace the PCB. at DIO extension is not per- formed. F.98 Function on digital input DI3 DIO extension PCB faulty Replace the PCB.
  • Page 109 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.185 Burner in a fault state Lead break, flow tempera- Check flow temperature sensor on ture sensor the burner control unit (see page 130). Reset burner.
  • Page 110 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.351 Burner in a fault state Ionisation current check Check ignition electrodes and con- necting cables. Check ionisation electrode and connecting cable. Reset burner. F.352 Burner in a fault state CO limit within appliance...
  • Page 111 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.357 Burner in a fault state Insufficient gas supply Test static gas pressure and gas flow pressure. Check that on-site gas line and gas flow switch are correctly sized.
  • Page 112 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.363 Burner in a fault state Flame signal is already Check system for condensate present at burner start. backup. Note To prevent water damage, detach fan unit before removing the burn- Check ionisation and ignition elec- trode for damage and earth faults...
  • Page 113 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.369 Burner in a fault state Flame is lost immediately Check gas supply (gas pressure after flame formation (dur- and gas flow switch). ing safety time).
  • Page 114 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.374 Burner in a fault state Stabilisation conditions for Check the ionisation electrode and pre-calibration not met connecting lead (see page 72). Check plug-in connections for loose contacts.
  • Page 115 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.375 Burner in a fault state Calibration failed Minimum Check the ionisation electrode and value or termination crite- connecting lead (see page 72). rion not reached Check plug-in connections for loose contacts.
  • Page 116 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.376 Burner in a fault state Error, factory setting limits Check the ionisation electrode and or excessive difference to connecting lead (see page 72). previous value Check plug-in connections for loose contacts.
  • Page 117 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.377 Burner in a fault state Stabilisation conditions for Check the ionisation electrode and re-calibration not met connecting lead (see page 72). Check plug-in connections for loose contacts.
  • Page 118 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.379 Burner in a fault state Flame signal is not Check gas supply (gas pressure ■ present or insufficient at and gas flow switch). burner start.
  • Page 119 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.385 Burner in a fault state Short circuit, signal 1, ioni- Check ignition electrodes and con- sation current necting cables. Check ionisation electrode and connecting cable.
  • Page 120 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.402 Burner in a fault state Lead break, ionisation Check ignition electrodes and con- voltage, signal 2 necting cables. Check ionisation electrode and connecting cable.
  • Page 121 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.425 System in control mode, cal- Time synchronisation Set the time. culation out of operation failed F.426 Burner in a fault state Short circuit, external un- Check connection to the burner lock signal control unit.
  • Page 122 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.452 Burner in a fault state Error in scheduled pro- Check ignition electrodes and con- gram run monitoring necting cables. Check ionisation electrode and connecting cable.
  • Page 123 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.463 Burner in a fault state Ionisation current too low Check the ionisation electrode and during calibration connecting lead (see page 72). Check plug-in connections for loose contacts.
  • Page 124 HMU con- trol unit. F.474 Burner in a fault state Error in scheduled pro- Check ignition electrodes and con- gram run monitoring necting cables. Check ionisation electrode and connecting cable. Reset burner. F.475 Fuel cell fault Notify Viessmann Technical Serv- ices.
  • Page 125 Troubleshooting Fault messages for gas condensing module (cont.) Fault number System characteristics Cause Measures on the display F.476 Fuel cell not generating pow- Heat build-up due to ex- Reduce ambient temperature. cessive ambient tempera- ture F.479 DHW heating and central Short circuit, motor, divert- Check diverter valve motor, con- heating possible to a limited...

  • Page 126: Fault Codes, Fuel Cell Module

    A8F0 No power generation Gas supply interrup- Check the gas supply. Other fault mes- Notify Viessmann Technical Services. sages Repairs Putting the control unit into the service position If required for commissioning and servicing, the pro- gramming unit can be moved to a different position.

  • Page 127: Draining The System On The Heating Water And Dhw Sides

    Troubleshooting Repairs (cont.) Fig. 76 Draining the system on the heating water and DHW sides Only when necessary for repair work. Draining gas condensing module on the heating water side Fig. 77...
  • Page 128 Troubleshooting Repairs (cont.) 1. Shut off connections on the heating water side. 2. Attach the supplied short hose to drain valve drain valve and connect to a drain. 3. Open drain valve Note If necessary, open the air vent valves on the two outer shut-off valves above the modules.
  • Page 129 Troubleshooting Repairs (cont.) Draining the fuel cell module system separation circuit 2. Turn off the ON/OFF switch on the fuel cell mod- ule. See page 58. 3. Attach the supplied short hose to fitting connect it to a drain. 4. Open the drain valve on the underside of fitting by turning screw to undo it and pulling it down- wards.

  • Page 130: Checking The Temperature Sensors

    Troubleshooting Repairs (cont.) Checking the temperature sensors Outside temperature sensor 4. Depending on the test result, replace the lead or the outside temperature sensor. Temperature sensors inside Vitovalor PT2 For the electrical connection of the temperature sen- sors, see connection and wiring diagrams from page 193.
  • Page 131 Troubleshooting Repairs (cont.) Fig. 84 3. Check the sensor resistance and compare it to the curve. 4. In the event of severe deviation replace the sensor. 5. Rotate sensor by turn to install it. ¼ Danger Escaping flue gas can cause poisoning. When restarting, check for leaks on the flue 10 30 50 70 90 110 gas side.

  • Page 132: Checking The Cylinder Loading Plate Heat Exchanger

    Troubleshooting Repairs (cont.) 2. If necessary, correct the position of the flue gas 3. Reset the burner and re-start. temperature sensor (bayonet fitting) or replace the The check is repeated until it is completed suc- faulty flue gas temperature sensor. Check for leaks cessfully.

  • Page 133: Removing The Flow Sensor

    Troubleshooting Repairs (cont.) Fig. 87 1. Shut off and drain the boiler on the heating water 4. Remove thermal insulation and DHW sides. See page 127. 5. Check the connections on the heating water and 2. Pivot the control unit forwards. See page 34. DHW sides for contamination and scaling;...

  • Page 134: Removing The Hydraulic Unit

    Troubleshooting Repairs (cont.) Removing the hydraulic unit In case hydraulic unit components have to be replaced. Fig. 89 Replacing the power cable When replacing the power cable, use the following cable type: H05V2V2-F 3 G 1.5 mm . Connection, see page 194.

  • Page 135: Checking The Fuse

    Troubleshooting Repairs (cont.) Checking the fuse 1. Turn off the gas condensing module ON/OFF switch. See page 58. 2. Release the side closures and pivot the control unit down. 3. Remove cover 4. Check fuse F1 (see connection and wiring dia- gram).
  • Page 136 Troubleshooting Repairs (cont.) Check flow temperature sensor 1. Disconnect plug from the extension kit. 2. Check the sensor resistance and compare it to the curve. In the event of severe deviation replace the sensor. Temperature in °C Fig. 92 Sensor type: NTC 10 k Ω...

  • Page 137: Parts Lists Overview Of Gas Condensing Module And Fuel Cell Module

    Parts lists Overview of gas condensing module and fuel cell module The following details are required when ordering parts: Assembly (from this parts list) ■ ■ Serial no. (see type plate ■ Position number of the individual part within the ■...

  • Page 138: Assembly, Vitovalor Sheet Metal Sections

    Parts lists Assembly, Vitovalor sheet metal sections 0009 0011 0008 0008 0008 0003 0008 0006 0002 0003 0008 0010 0007 0008 0005 0008 0010 0001 Fig. 94...
  • Page 139 Parts lists Assembly, Vitovalor sheet metal sections (cont.) Pos. Part 0001 Outer casing sheet metal sections 0002 Cover panel with gaskets and label 0003 Profiled seal 15 l = 520 0005 SLM set seating 0006 Toggle fastener set (4 pce) 0007 Pipe clip holder 0008...

  • Page 140: Casing Assembly

    Parts lists Casing assembly 0002 0003 0012 0010 0011 0004 0011 0012 0008 0013 0009 0014 0005 0006 0001 Fig. 95...
  • Page 141 Parts lists Casing assembly (cont.) Pos. Part 0001 Adjustable foot, M12 x 19 0002 Top panel 0003 Side panel, left 0004 Side panel, right 0005 Programming unit mounting bracket 0006 Front panel, bottom 0008 Contact guard 0009 Body-bound rivet 0010 Front panel, top 0011 Insert, front panel, top...

  • Page 142: Heat Cell Assembly

    Parts lists Heat cell assembly 0010 0011 0009 0010 0001 0019 0024 0005 0003 0019 0025 0002 0003 0004 0003 0003 0002 0008 0016 0003 0015 0007 0003 0021 0008 0006 0015 0003 0014 0017 0012 0013 0013 0015 0020 0015 0015 0019...
  • Page 143 Parts lists Heat cell assembly (cont.) Pos. Part 0001 Heat cell module 0002 Diaphragm grommet 21/70 0003 Gasket A 17 x 24 x 2 (5 pce) 0004 Gas pipe 0005 Gas pipe 0006 Angle gas valve G 3/4 0007 Gas supply pipe 0008 Gasket 13 x 18 x 2 (5 pce) 0009...

  • Page 144: Heat Cell Module Assembly

    Parts lists Heat cell module assembly 0005 0004 0006 0001 0007 0006 0006 0012 0008 0012 0002 0001 0003 0005 0010 0006 0007 0008 0010 0011 0003 0011 0009 Fig. 97...
  • Page 145 Parts lists Heat cell module assembly (cont.) Pos. Part 0001 Connection elbow HR (heating return) 0002 Heat exchanger 0003 Thermal insulation block with MultiTherm 0004 Flue gas temperature sensor 0005 Flue gasket 0006 Connection elbow gasket set (2 + 2 pce) 0007 Connection elbow HV (heating flow) 0008...

  • Page 146: Burner Assembly

    Parts lists Burner assembly 0001 0003 0013 0005 0003 0013 0006 0002 0007 0003 0013 0004 0008 0003 0007 0007 0009 0011 0009 0013 0015 0010 0009 0015 0013 0011 0014 0013 0012 0011 0013 0013 Fig. 98...
  • Page 147 Parts lists Burner assembly (cont.) Pos. Part 0001 Cylinder burner gauze assembly 0002 Thermal insulation ring 0003 Gaskets and screws (set) 0004 Burner door 0005 Ignition unit 0006 Blade terminal (5 pce) 0007 Gasket, ignition electrode (3 pce) 0008 Ignition electrode block 0009 Gasket, ionisation electrode (3 pce) 0010...

  • Page 148: Vitovalor Hydraulic Assembly

    Parts lists Vitovalor hydraulic assembly 0003 0001 0001 0004 0002 0005 0006 0001 0007 0008 0008 0013 0004 0007 0005 0007 0013 0009 0008 0009 0010 0014 0024 0011 0008 0012 0007 0007 0008 0011 0015 0013 0007 0018 0014 0013 0008 0014...
  • Page 149 Parts lists Vitovalor hydraulic assembly (cont.) Pos. Part 0001 Clip 8 (5 pce) 0002 Temperature sensor 0003 Heat exchanger connection pipe 0004 Clip 18 (5 pce) 0005 O-ring 17 x 4 (5 pce) 0006 Diaphragm grommet (5 pce) 0007 O-ring 17.86 x 2.62 (5 pce) 0008 Pipe clips (2 pce) 0009...

  • Page 150: Hydraulic Assembly

    Parts lists Hydraulic assembly 0001 0010 0004 0010 0005 0006 0002 0003 0005 0009 0010 0002 0005 0006 0003 0009 0008 0011 0002 0003 0009 0007 Fig. 100...
  • Page 151 Parts lists Hydraulic assembly (cont.) Pos. Part 0001 Circulation pump quick-action air vent valve 0002 O-ring 19.8 x 3.6 (5 pce) 0003 Screw PT 50 x 12 (5 pce) 0004 Safety valve 3 bar 0005 Circulation pump motor 0006 Return casing 0007 Pressure sensor 0008...

  • Page 152: Control Unit / Electrical Components Assembly

    Parts lists Control unit / electrical components assembly 0006 0014 0005 0007 0005 0002 0001 0002 0003 0008 0003 0009 0012 0011 0010 0013 Fig. 101...
  • Page 153 Parts lists Control unit / electrical components assembly (cont.) Pos. Part 0001 Control unit bracket with BCU bracket 0002 Hinge 0003 Screw PT 50 x 12 (5 pce) 0005 HMU/MCU/BCU (control unit and burner control unit) 0006 HMI 961 programming unit 0007 Mains distributor box 0008...

  • Page 154: Hmu/Mcu/Bcu (Control Unit And Burner Control Unit) Assembly

    Parts lists HMU/MCU/BCU (control unit and burner control unit) assembly 0010 0011 0006 0003 0002 0004 0003 0005 0004 0005 0001 Fig. 102...
  • Page 155 Parts lists HMU/MCU/BCU (control unit and burner control… (cont.) Pos. Part 0001 HMU/MCU control unit enclosure with PCB 0002 Cable cover with catch 0003 Catch, back panel 0004 Fuse 6.3 A (slow) 250 V (10 pce) 0005 Grommets (10 pce) 0006 Plug-in connector 0010...

  • Page 156: Mains Distributor Box Assembly

    Parts lists Mains distributor box assembly 0001 0002 0002 Fig. 103...
  • Page 157 Parts lists Mains distributor box assembly (cont.) Pos. Part 0001 Mains distributor box 0002 ALD1 AC meter 32 A...

  • Page 158: Hmi Programming Unit Assembly

    Parts lists HMI programming unit assembly 0004 0003 0001 0003 0002 Fig. 104...
  • Page 159 Parts lists HMI programming unit assembly (cont.) Pos. Part 0001 Programming unit with frame 600 mm 0002 RF module 0003 Ribbon cable 0004 Programming unit fibre optic cable...

  • Page 160: Fuel Cell Assembly

    Parts lists Fuel cell assembly 0001 0006 0004 0005 0002 0003 0007 Fig. 105...
  • Page 161 Parts lists Fuel cell assembly (cont.) Pos. Part 0001 Distilled water 5 l 0002 Distilled water cartridge 0003 Air filter 0004 Air filter B 0005 CO sensor 0006 Flammable gases sensor 0007 5-yearly maintenance package Note For 5-yearly maintenance, order items pos. 0001 and ■...

  • Page 162: Miscellaneous Assembly

    Parts lists Miscellaneous assembly 0004 0005 0001 0002 0003 0006 Fig. 106...
  • Page 163 Parts lists Miscellaneous assembly (cont.) Pos. Part 0001 Operating instructions 0002 Installation and service instructions 0003 Heat conducting paste 0004 Touch-up spray paint, Vitosilver, 150 ml can 0005 Vitosilver touch-up paint 0006 Special grease...
  • Page 164 Parts lists Miscellaneous assembly (cont.)

  • Page 165: Overview Cylinder Module

    Parts lists Overview cylinder module The following details are required when ordering parts: Assembly (from this parts list) ■ ■ Serial no. (see type plate ■ Position number of the individual part within the ■ Fuel cell serial no. (see type plate assembly (from this parts list) Fig.
  • Page 166 Parts lists Overview cylinder module (cont.) Cylinder module Vitovalor cylinder module Miscellaneous...
  • Page 167 Parts lists Overview cylinder module (cont.)

  • Page 168: Casing Assembly Dcf 180 D1

    Parts lists Casing assembly DCF 180 D1 0002 0003 0004 0005 0006 0001 Fig. 108...
  • Page 169 Parts lists Casing assembly DCF 180 D1 (cont.) Pos. Part 0001 Adjustable foot M 12 x 19 (4 pce) 0002 Top panel 0003 Side panel, left 0004 Side panel, right 0005 Seal cover 0006 Front cover...

  • Page 170: Cylinder Module Pcb With Mounting Plate Assembly

    Parts lists Cylinder module PCB with mounting plate assembly 0001 0007 0001 0001 0007 0007 0001 0001 0007 0001 0001 0001 0001 0001 0002 0004 0006 0003 0005 Fig. 109...
  • Page 171 Parts lists Cylinder module PCB with mounting plate assembly (cont.) Pos. Part 0001 Self-tapping screws 0002 Cable, cylinder loading pump 0003 Cable harness, diverter valve 0004 Lead, return temperature sensor 0005 Power cable M2IO 0006 Bus cable 0007 Support panel M2IO tower cylinder 0008 Support panel M2IO rail...

  • Page 172: Cylinder Module Pcb Assembly

    Parts lists Cylinder module PCB assembly 0002 0003 0001 Fig. 110...
  • Page 173 Parts lists Cylinder module PCB assembly (cont.) Pos. Part 0001 M2IO extension module 0002 Casing top 0003 Fuse, 4.0 A (slow), 250 V (10 pce)

  • Page 174: Vitovalor Hydraulics Assembly

    Parts lists Vitovalor hydraulics assembly 0021 0012 0001 0005 0012 0026 0002 0005 0003 0002 0010 0008 0016 0003 0002 0014 0001 0002 0006 0018 0011 0019 0004 0009 0019 0003 0015 0002 0004 0008 0006 0009 0018 0019 0025 0017 0020 0013...
  • Page 175 Parts lists Vitovalor hydraulics assembly (cont.) Pos. Part 0001 O-ring 17.86 x 2.62 (5 pce) 0002 Profiled gasket (4 pce) 0003 Clip 8 (5 pce) 0004 Clip 15 (5 pce) 0005 Clip 18 (5 pce) 0006 O-ring 14.3 x 2.4 (5 pce) 0007 Gasket 23 x 30 x 2 (5 pce) 0008...

  • Page 176: Hydraulics Assembly, System Separation Circuit

    Parts lists Hydraulics assembly, system separation circuit 0019 0019 0019 0016 0016 0036 0019 0016 0016 0023 0019 0017 0013 0016 0017 0017 0035 0019 0016 0040 0019 0019 0017 0013 0016 0033 0013 0002 0004 0004 0002 0008 0032 0016 0019 0017...
  • Page 177 Parts lists Hydraulics assembly, system separation circuit (cont.) Pos. Part 0001 Temperature sensor 0002 Pipe clips (2 pce) 0003 Clip 140 - 160 0004 O-ring 17.86 x 2.62 (5 pce) 0005 Profiled gasket (4 pce) 0006 Clip 8 (5 pce) 0007 Clip 15 (5 pce)

  • Page 178: Cylinder Module Assembly

    Parts lists Cylinder module assembly 0009 0014 0002 0009 0003 0010 0011 0012 0012 0009 0014 0015 0011 0010 0005 0001 0009 0002 0014 0015 0014 0001 0011 0010 0014 0012 0003 0010 0011 0012 0014 0014 0014 0014 0012 0006 0014 0004...
  • Page 179 Parts lists Cylinder module assembly (cont.) Pos. Part 0001 Circulation pump motor VIUP - 30 0002 CIL2 casing 0003 Right-angle shut-off valve, cylinder 0004 Shut-off valve HW 0005 RV cartridge (non-return valve) 0006 Right-angle shut-off valve G 3/4 0007 Hose nozzle 1/2 0008 Cylinder temperature sensor NTC 0009...

  • Page 180: Cylinder Assembly

    Parts lists Cylinder assembly 0006 0005 0004 0003 0002 0001 0007 Fig. 114...
  • Page 181 Parts lists Cylinder assembly (cont.) Pos. Part 0001 Stainless steel cylinder 220 l 0002 Strain relief 0003 Gasket 0004 Circular blank 0005 Cylinder cap 0006 Cylinder cap thermal insulation 0007 Cylinder temperature sensor NTC 10 k...

  • Page 182: Vitovalor Cylinder Module Assembly

    Parts lists Vitovalor cylinder module assembly 0006 0001 0006 0002 0008 0006 0005 0006 0006 0006 0008 0002 0013 0007 0011 0005 0007 0008 0008 0007 0008 0001 0018 0002 0014 0008 0018 0012 0002 0002 0004 0019 0020 0001 0018 0003 0018...
  • Page 183 Parts lists Vitovalor cylinder module assembly (cont.) Pos. Part 0001 Pipe clips (2 pce) 0002 O-ring 17.86 x 2.62 (5 pce) 0003 Gasket 23 x 30 x 2 (5 pce) 0004 Cap G 3/4 0005 Pipe clip 0006 Retaining clip 0007 Screws 0008...

  • Page 184: Side Mounting Kit Assembly

    Parts lists Side mounting kit assembly 0015 0002 0014 0003 0002 0015 0003 0015 0002 0014 0003 0003 0002 0015 0003 0010 0015 0002 0003 0014 0015 0014 0009 0002 0003 0002 0003 0003 0008 0003 0015 0015 0015 0003 0003 0015 0014...
  • Page 185 Parts lists Side mounting kit assembly (cont.) Pos. Part 0001 Edge protection 0002 Pipe clips (2 pce) 0003 O-ring 17.86 x 2.62 (5 pce) 0004 Gasket 17 x 24 x 2 (5 pce) 0005 Straight-through gas valve with TSV 0006 Retaining clip 0007 Connection pipe, tower cylinder connection...

  • Page 186: Function Description Control Unit

    Function description Control unit Heating mode The control unit determines a set flow temperature for The electronic temperature limiter inside the burner the heat generator, subject to the outside temperature control unit limits the flow temperature. or the room temperature and the slope/level of the heating curve.

  • Page 187: External Extensions (Accessories)

    Function description External extensions (accessories) EM-EA1 extension Fig. 117 Digital input 1 Rotary switch for subscriber number Digital input 2 Relay output 230 V with input 230 V (no function) Power supply fÖ Digital input 3 (no function) Power supply for additional accessories fÖ...

  • Page 188: Filling Program

    Function description Control functions (cont.) To activate the venting program: See "Venting the heating system". Filling program In the delivered condition, the diverter valve is set to its Filling with the control unit switched on central position, so the system can be filled completely. After the control unit has been switched on, the If the system is to be filled with the control unit diverter valve no longer goes into its central position.

  • Page 189: Raising The Reduced Room Temperature

    Function description Control functions (cont.) Temperature profile 3 Days Fig. 120 Temperature profile 4 Days Fig. 121 Temperature profile 5 Days Fig. 122 Temperature profile 6 Days Fig. 123 Ends after 21 days Raising the reduced room temperature During operation at reduced room temperature, the The outside temperature limits for the start and end of reduced set room temperature can be automatically temperature raising can be set in parameters 1139.0...
  • Page 190 Function description Control functions (cont.) Example using the settings in the delivered condition Outside temperature in °C Fig. 124 Heating curve for operation at standard room tem- perature or comfort room temperature Heating curve for operation at reduced room tem- perature Reducing the heat-up time The value and duration of the additional increase in the...

  • Page 191: Electronic Combustion Controller Of Gas Condensing Module

    Function description Control functions (cont.) Example Time Fig. 125 Start of operation at standard room temperature or Set flow temperature in accordance with parame- comfort room temperature ter 424.3 Set flow temperature in accordance with the set Duration of operation with higher set flow tempera- heating curve ture in accordance with parameter 424.4: 60 min...

  • Page 192: Electrical Output Of The Fuel Cell

    Function description Electronic combustion controller of gas… (cont.) To achieve optimum combustion control, the system regularly carries out an automatic self-calibration; also after power failures (shutdown). For this, the combus- tion is briefly regulated to maximum ionisation current (corresponding to air ratio =1).

  • Page 193: Connection And Wiring Dia-Overview Connection Diagrams

    Connection and wiring diagram Overview connection diagrams Fig. 126 Mains distributor box M-Bus gateway Control unit, gas condensing module EM-P1 or EM-EA1 extension Burner control unit Fuel cell module junction box Programming module SA 191 extension Cylinder module control unit A10 Filter box...

  • Page 194: Gram Mains Distributor Box

    Connection and wiring diagram Mains distributor box Fig. 127 A1 Mains distributor box Gas condensing module control unit Z1 Electricity meter Fuel cell control unit Power supply...

  • Page 195: Connection Diagram, Gas Condensing Module Control Unit

    Connection and wiring diagram Connection diagram, gas condensing module control unit Fig. 128 Control unit, gas condensing module Floating input 230 V and output 230 V Programming module Mains voltage output Switching mode power supply Parametrisable output for e.g. circuit pump for A10 Filter box CAN heating circuit without mixer X...

  • Page 196: Connection Diagram, Burner Control Unit

    Connection and wiring diagram Connection diagram, gas condensing module… (cont.) To the fuel cell module To the M-Bus gateway Connection diagram, burner control unit Fig. 129 PWM Control signal Ionisation electrode X... Electrical interfaces Flue gas temperature sensor A/B Flow temperature sensors 1 and 2 Boiler circuit pump §...
  • Page 197 Connection and wiring diagram Connection diagram, burner control unit (cont.) Gas solenoid valve Water pressure sensor Power supply A Water pressure sensor fÖ Ignition unit Burner control unit Fan motor Gas condensing module control unit (plug a-Ö a-Ö A Fan motor control Gas condensing module control unit (plug X4)

  • Page 198: Connection Diagram, Cylinder Module Control Unit

    Connection and wiring diagram Connection diagram, cylinder module control unit Fig. 130 Cylinder module control unit DHW circulation pump SA 191 extension No function Cylinder module control unit PCB No function SA 191 extension PCB PWM1 No function Cylinder loading pump PWM2 No function...
  • Page 199 Connection and wiring diagram Connection diagram, cylinder module control unit (cont.) Rotary switch Mains voltage output fÖ A Top cylinder temperature sensor PlusBus B Bottom cylinder temperature sensor To the gas condensing module control unit No function (plug System return temperature sensor To the gas condensing module control unit No function (plug...

  • Page 200: Commissioning/Service

    Commissioning/service reports Commissioning/service reports Settings and test values Commis- Mainte- Maintenance/ Maintenance/ value sioning nance/ service service service Date Signa- ture Static pressure mbar ≤ ≤ Supply pressure (flow pres- sure) For natural gas E mbar 17.4-2 For natural gas LL 1.74-2.

  • Page 201: Specification

    Specification Specification Rated heating output Gas condensing boiler (TV/TR 60/40 °C) 11.4 19.0 24.5 30.8 th max. (TV/TR 36/30 °C) th min. Rated heating input range 2.0 - 12.3 2.0 - 19.8 2.0 - 25.4 2.0 - 31.9 Rated heating input range for DHW heating 2.0 - 31.9 2.0 - 31.9 2.0 - 31.9...

  • Page 202: Disposal Final Decommissioning And Disposal

    Disposal Final decommissioning and disposal Viessmann products can be recycled. Components For decommissioning the system, isolate the system and substances from the system are not part of ordi- from the power supply and allow components to cool nary household waste.

  • Page 203: Certificates Declaration Of Conformity

    Certificates Declaration of conformity We, Viessmann Werke GmbH & Co. KG, D-35107 Using the serial number, the full Declaration of Con- Allendorf, declare as sole responsible body that the formity can be found on the following website: named product complies with the European directives www.viessmann.co.uk/eu-conformity...

  • Page 204: Keyword Index

    Keyword index Keyword index Air filter replacement..........76 Fault codes Appliance – Gas condensing module........104 – Aligning..............24 Faults............... 103 – Splitting..............44 – Fuel cell module............ 126 Filling function............188 Filling program............54 Bidirectional meter......16, 17, 18, 19, 22 Fill water..............52 Boiler, draining............
  • Page 205 Keyword index Keyword index (cont.) Mains parallel mode........... 15 Passwords Mains power, switching on......... 58 – Factory setting reset..........98 Maintenance mode.............64 Plate heat exchanger..........132 Manufacturer's certificate......... 203 Positioning..............8 Message history............103 Power distribution........17, 18, 19, 21 Meter cupboard............16 Power supply..............40 Mixer open/closed............
  • Page 206 Keyword index Keyword index (cont.) WLAN connection............60 Venting program............187 WLAN network............60 Water circuits..............50 Wiring diagram............195...
  • Page 208 Viessmann Werke GmbH & Co. KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040 E-mail: info-uk@viessmann.com...

This manual is also suitable for:

Vitovalor pt2 seriesVitovalor pt2 e19tVitovalor pt2 e25tVitovalor pt2 e32t

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